Catalyst spray gun and method of spraying resins



3,066,874 CATALYST SPRAY GUN AND METHOD OF SPRAYING RESINS Filed Oct. 5, 1960 R. M. BECKER Dec. 4, 1962 3 Sheets-Sheet l 4 4 Aw... 4 el@ hal/1% INVENTOR. P/f/APD M BECA/EE A rraeA/Eys Dec. 4, 1962 R. M. BECKER 3,066,874

CATALYST SPRAY GUN AND METHOD OF SPRAYING RESINS Filed Oct. 5, 1960 3 Sheets-Sheet 2 INV EN TOR. /Q/CHA 2D M BECKE BY l @zw fa@ M 46%,.;

ATTORNEYS R. M. BECKER Dec. 4, 1962 3,066,874 CATALYST SPRAY GUN AND METHOD OF' SPRAYING RESINS Filed Oct. 5, 1960 5 Sheets-Sheet 5 INVENTOR. E/CHA ED M. BEC/ 51? 3,066,874 CATALYST SPRAY GUN AND METHOD 0F SPRAYlNtG RESlNS Richard M. Becker, Willoughby, Gillo, assigner, by mesne assignments, to lhis Enterprises Limited, Hamilton, Bermuda, a corporation of Bermuda Filed 0st. S, 196i), Ser. No. 60,691 lil Claims. (Ci. Z39- 14%) This invention relates to improvements in a spray gun for a plurality of fluids which are kept separate during their progress through the gun and are mixed only in the spray pattern as they leave the gun and before they are deposited on a desired surface. More particularly, the invention provides means located at the gun itself for quickly and accurately setting the rate of discharge of the various fluids whereby a critical ratio of the cornponent fluids may be readily established and maintained, and may be readily reset for a repeat performance.

Synthetic resins are available today which may be readily deposited in desired forms and patterns to give exceptionally fine properties to the finished product. However, many of these resins require a catalyst or other additive to cause the material to set in its final form. Because of the quick reaction of this catalyst component, it is undesirable, or in some cases impossible, to mix the catalyst in the pot before spraying and the desired condition is to mix the catalyst with the basic material, such as resin, in the spray itself so that it sets immediately upon striking the surface where it is deposited. Sometimes, the ratio between the synthetic resin or lbase material and its catalyst or hardener is of such a critical nature that a relatively slight deviation from this critical ratio destroys the value of the work.

It is an object of the present invention to provide a spray gun for dispensing simultaneously a plurality of component lluids which are mixed only after they leave the spray gun, and wherein means are provided directly at the gun itself and under the immediate control of the operator for settinU the rate of discharge of each of the component fluids separately, together with indicator means to show that the critical ratio is being maintained and to provide for quick resetting of critical ratios when desired.

Other objects and advantages of the present invention will be apparent from the accompanying drawings and description and the essential features thereof will be set forth in the appended claims.

This application is a continuation-in-part of my copending application Serial No. 20,454, filed April 6, 196i), now abandoned, for Catalyst Spray Gun and Method of Spraying Resins.

ln the drawings- FIG. 1 is a central sectional view through one embodiment of my invention;

FIG. 2 is an end view of the device of FIG. 1 taken from the position of the line 2-2 of FIG. l;

FIG. 3 is a central sectional View through another embodiment of my invention showing the fluid component discharge orifices of the gun in closed condition;

FIG. 4 is a sectional View similar to FIG. 3 but showing the fluid component discharge ports open:

FIG. 5 is a central sectional view through still another embodiment of my invention; while FIG. 6 is an enlarged fragmental sectional view of parts associated with the piston in FIG. 5.

Referring now to FiGS. l and 2, a resin lluid body l@ is provided near the tip end of the gun and having a central opening communicating with a resin fluid supply passageway Ill which is fitted to receive a hose or the like through which resin may be fed to the gun under pressure as desired. A resin fluid tip l2 is threaded into lnite States Patent O ICC the body lll and has walls which taper forwardly in a somewhat conical fashion to terminate at the forward end thereof in a generally circular opening 13. A generally conical shaped air cap 14 is secured to the body it) by means of the air cap nut l5. This air cap nut terminates in a generally circular opening ld at its forward end, this opening being larger than the forward end of the tip l2 so as to provide an annular space for the discharge of air entirely around the resin fluid tip.

To the rear end of the resin fluid body l@ there is secured a catalyst fluid body i7 by means of retaining ring 18 and a cap nut i9. This body 17 is provided with a catalyst fluid supply passage 2.5i which is arranged for the connection of a hose or the like to feed catalyst to the gun under pressure as desired.

To the rear end of the catalyst body i7 a cylinder 2i is secured, as by threading the solid body portion Zia to the body 17. This cylinder is provided with an air inlet 22 arranged for the connection of an air hose or the like. The rear end of the cylinder is closed by the threaded cylinder cap 23. The cylinder is fitted with a piston comprising a piston nut Z4 having a flange 24a lying on the rear side of a piston leather ZS, on the other side of which is a disk 26 which has a hub threaded into the nut 24 so as to firmly hold the leather between them. A helical compression spring 27 lies between the cylinder cap 23 and the piston nut 2li so as to urge the piston forwardly when it is released from air pressure in the cylinder.

A central, axially extending cylindrical opening is provided through the bodies lil, i7 and 2M in alignment so as to receive a hollow needle 2d. This needle is provided with an axially extending opening 29 of small diameter from the tip end thereof back to a needle valve seat 3S in the mid-portion of the catalyst fluid body i7 adjacent the catalyst inlet passage Ztl. At this point the needle is surrounded by an annular chamber 3l in the body 17 from which a plurality of openings 32 communicate with the hollow portion of the needle to permit the entrance of catalyst past the valve seat and down the passageway 29 when the needle valve is open. This needle valve 33 occupies a larger diameter bore in the needle 28 and extends through the piston nut 24 where it is increased in diameter and provided with a threaded connection with the nut 24 as indicated at 3d so that when a hand knob 35 fixed to the rear end of the needle valve 33 is turned, the threaded connection at 34 is adjusted to regulate the amount which the needle valve will leave its seat 3th when actuated as later described.

lt is obvious that needle valve 33 will be lifted from its seat 30, through its'threaded connection with the piston nut 2st, when the piston is moved rearwardly by the introduction of air to the forward portion of cylinder 21 through passageway 22.

A second connection is provided with the piston for the operation of the hollow needle 28 by actuation of the piston. This comprises a collar nut 36 which is threaded to the disk 26 and provides an inwardly extending flange adapted to underlie the radially outwardly extending flange 2da at the rear end of the hollow needle 2S. A lost motion is provided between the parts 36 and 28a as indicated at 37 so that the first movement rearwardly of the piston will lift the needle valve 3? off its seat 30, and quickly thereafter nut 36 will engage flange 28a to move the hollow needle rearward so as to open up an annular opening at the tip end of the hollow needle between the end of the needle and the fluid tip l2.

Means is provided to limit the rearward movement of the piston so as to control the opening of the needle 28 and of the needle valve 33. This is an abutment which is provided by the hollow stem 3S which is threaded into a friction nut 39 which in turn is threaded to a hub on spettava the cylinder cap 23. The rear end of stein 38 terminates in a hand knob 33a by which the stem may be run in or out on its threads so as to adjust the space d@ between the end of the stem 38 and the rear portion of the piston nut 24. A helical compression spring 4l between the members 38a and 39 surrounds the stern 38 and provides a friction resistance so as to give better adjustment of the knob 38a and its indicator dial presently to be described.

To indicate the adjustment or" the knob 38a., a resin uid indicating dial is slipped on the extension of cylinder cap 23 as indicated and provided with indicia as shown in FIG. 2. A pointer 43 on the knob 33a serves to advise the operator as to what adjustment he has made and serves to reset the same adjustment at any time in the future as desired by the operator. A Spring washer 42a maintains friction against dial indicator means is also provided to indicate the amount of the threaded adjustment at 3d which limits the movement of the needle valve 33. A sleeve 44 freely surrounds the rear end of the needle valve 33 and is a press t in the nut 24. Threaded on the rear end of this sleeve is a spacer nut 45 on which is secured an indicator dial 46 provided with indicia as shown in FlG. 2. A pointer 47 on the knob 35 serves to indicate the adjustment of the needle valve in the thread 34 so as to control the lifting of the needle valve from its seat 3o by a predetermined aITlOllIlt.

Means is provided to supply air into the spray at the tip end of the gun simultaneously with the application of air to the cylinder 2l to initiate the spraying action. This comprises a pluraliy of longitudinally extending air passages d8 in the solid portion at the front end of cylinder 2,1 leading to an annular passage .191 This passage leads to a similar passage in the body 17 where one or more axially extending air passages are provided extending forF wardly through the body 17 to a second annular passageway Si. where the junction takes place with the body 10. One or more air passageways 52 are provided through the body it) leading forwardly and communicating with the space inside the air cap i4. This provides the air which is discharged at the end space lo between the air cap and uid tip L2. For controlling the fan or pattern of the spray during operation, a fan screw 53 is provided for controlling. a needle valve 54 which controls the inlet of air from the passageway 52 into the air cap.

Suitable sealing means is provided at 55 to prevent the leakage of resin or catalyst along the outer surface of the hollow needle 23. ln a like manner suitable sealing means is provided at d` to prevent the passage of catalyst or air along the outer surface of the hollow needle 2S. Other suitable packing is provided at 57 to prevent the leakage of air or catalyst along the outer surface of the needle valve 33.

The operation of the form of device shown in FIGS. 1 and 2 should now be apparent. With a source of resin or other base material connected at ll, with a source of catalyst or other hardening material connected at 2li, and with a source of air or other uid pressure connected at 22, the device is ready to operate. The operator introduces air through the connection 22 by means of a control valve, not shown, thus causing the piston to move rearwardly. The rst action of the piston is to lift the needle valve 33 from its seat 3d by means of the threaded connection 34 according to the adjustment set by the knob 35. As soon as the lost motion 37 is taken up, which iS almost immediately, the parts 36 and 23a are engaged to pull the hollow needle 28 rearwardly so as to open up the resin flow around the tip end of the needle 2S inside the uid tip l2. The amount of this opening is set by the adjustment on the hollow stem 38 by means of its knob 38a. This controls the distance dit which is closed when the nut 24 strikes the stem 38 and controls the inlet of the uid component entering at lill. Simultaneously with the introduction of air to the cylinder 21, the air ows through the indicated passages to the air cap 14 and emerges at i6 to controi the fan or pattern of the air spray which thoroughly intermingles the two iiuid components introduced at il and 2t), respectively. Because the fluid component introduced at il needs no catalyst or hardening agent in the pot, it has a long pot life. Because the component introduced at lll and the catalyst component or hardening agent introduced at 20 are no-t commingled until they leave the spray gun, there is no problem of the plugging up of the spray gun. Because the needle valve 33 is opened rst and closed last, there is no problem of the resin material from l. clogging up the tip of the gun or being sprayed without the catalyst or hardening component. Because of the power operation of the gun, the lost motion 37 is taken up so quickly that the discharge of the two spra,I components introduced at it and Ztl is substantially simultaneous and avoids any problem in case a single one of these components should reach the job alone without being mixed with the other component.

Because of the combination of the pointer 43 and the indicator dial d2 together with the pointer 47 and its indicator dial 46, the operator can quickly make positively indicated adjustments for the flow of the two components or can readily reset a previous adjustment if he has marked down or remembered the dial settings at d?. and 46.

A slightly different embodiment of my invention is shown in FIGS. 3 and 4. Since many of the parts are identical in character and function with those just described, all of such parts have been given identical reference characters with those described in connection with FEGS. 1 and 2 and are understood to have identical functions with those already described in connection with the i'lrst form of the invention.

One difference is that the rear end of the nee vle valve 33 is threaded at 34 into the piston nut Zd in a fixed manner so that it is not adjustable as shown in FEC. l. Here the adjustment of the catalyst feed through the passageway 21) is provided by means of a connecting `tube o@ provided with a reduced passageway di through which flow is controlled by a needle valve d2 having a control knob 63. Suitable packing is provided at heid in place by the packing nut 65. This provides a control knob 63 right at the gun itself and under the immediate control of the operator so as to adjust the flow or" the catalyst through passages Ztl', 3l, 32 and 29 to the tip end oi the gun.

The means provided for limiting the rearward movement of the piston in the cylinder comprises a screw 66 threaded into a friction nut 39' which in turn is threaded onto an extension of the cylinder cap 23. This provides an abutment opposite the rear end of the nut 2d. By adjusting this screw the space 67 is adjusted, which limits the rearward movement of the piston when air is supplied to the cylinder 2l. An indicator dial 42 like the previously mentioned dial 42 is virictionally held between the nut 39 and a resilient spring washer 42a. A helical spring 4l. creates a friction holding pressure for the screw 66. The head of this screw is provided with a pointer 43 which coacts with the indicia on the dial d2 to indicate the adjustment of the space w57.

ln FIG. 4 the operated position of the parts of the device of FIG. 3 is shown. With resin or other base material supplied at 1i, with catalyst or other hardening material supplied at E@ and with air supplied at 22 the operator actuates an air valve (not shown) to admit air to the forward end ot cylinder 21 and move the piston backwardly. The rst movement of the piston lifts the needle valve 33 from the seat 3i) permitting catalyst to ow from the passageway Ztl to the tip of the gun through the passageway 29. Immediately thereafter, the lost motion 37 is taken up so that the members 36 and 23a engage each other to move the hollow needle 2S to open position for ow of resin out the annular opening i3. Simultaneously with the introduction of air in the cylinder 2l, kit

apodera flows through the passageways 4S, 49, Sil, 5l, 5.?. into the air cap 14 to be discharged into the sprayed components at 6b. This spray or fan pattern is controlled by the tan screw 53 previously described. Upon the discontinuation of the air supply through the connection 2?., the spring 27 returns the parts to closed position as shown in FlG. This action was not described in connection t ith FlG. l but the same valve closing action taires place there under the same spring 217.

Obviously, pointers and dial indicators could be used in connection with the adjustments at d3 and if desired.

Another form of my invention is shown in FlGS. 5 and 6. Here the resin fluid body lll has a central opening communicating with a resin lluid supply passageway ll, a resin fluid tip l2 threaded into the body it), terminating in a generally circular discharge opening i3, a generally conical shaped air cap A held on the body itl by means of the air cap nut 1S, with the air cap nut terminating in a generally circular opening lo at its forward end, this opening being larger than the forward end of the tip 12 so as to provide an annular space for the discharge of entirely around the resin tluid tip, all as previously de scribed in connection with FIGS. l and 2.

To the rear of the body l0, a cylinder 2id is secured, as by threading the solid body portion 21de: to the body lb. This cylinder is provided with an air inlet 22d arranged or the connection of an air hose or the like. The rear end or the cylin is closed by the threaded cylinder cap 23d. This cylinder is fitted with a piston comprising a piston nut ffl-'ttl having a frange lying on tale rear side of the piston leather 25d, on the other side ot which is a disk Zoll which has a hub threaded into the nut 2d@ so as to firmly hold the le ther between them. A helical compression spring .77@ lies between the cap 23d and the piston nut Z-/ill so as to urge the pistou forwardly when it is released from air pressure in the cylinder.

A central, axially extending cylindrical opening is provided through the bodies lll and Zilla in alignment so as to receive a hollow needle 7,*3. This needle is provided with an axially extending opening 7l of small diameter from the tip end thereof back to a needle valve seat 72, intermediate the ends of the needle. Rearwardly of this point the central opening of the needle is enlarged by means of a hollow sleeve 73 which is permanently secured either as by welding or by a pressed t to the needle 70. The rear end of this sleeve 73 has a flange 73a ente ding radially outwardly and fitting with lost motion w hin a recess 75m formed in a piston extension 74 which is threaded into the piston nut 24%. A needle valve 75 axially aligned with the passageway 7l is a press lit in the member 75l. A packing gland spring pre` by a spring 77 is provided between the needle valve 75 and the internal hollo-w of sleeve 73 so as to prevent the leakage oi any luid there. Near the forward end of the needle valve 75 there is provided one or more openings 7S communicating with a hollow central passageway 79 in the needle valve which communicates with a central passage way 74th extending rea /vardly `through the member '7d at the rear end of which it communicates with a passaeeway fill in a valve block ill which is threaded to the rear end of the member '74. ln this valve block is provided a needle valve seat 8?, closed by an adgustable needle valve 83 and communicating rearwardly with a connection bd through which a catalyst may be supplied as presently explained.

Means is provided to limit the rearward moyen-rent of the piston so as to control the opening of the needle 70. rThis is an abutment provided by the hollow stem 8:3' which is threaded into an extension of the cap 23%. This stern is integral with a head 85a which carries a pointer 85h to indicate the setting of the stop shoulder S50. This indication is given by means of a disk S5 which is threaded on the extension of cap 23d and carries suitable indicia. Once a setting is arrived at it is maintained by means of the friction nut 37 which is threaded on the stem A d helical spring Si?, in compression between the nut S7 and the head 85a, maintains a rictional resistance so as to give better adjustment of the head or control knob 35u when setting the position of the abutment shoulder SSC.

The means for providing an air supply to the annular opening i6 at the discharge end of the gun is similar to that previously described. This comprises a plurality of longitudinally extending air passages 89 in the cylindrical extension Zilla, these passages providing communication from the air pressure chamber in cylinder 2310 forwardly to an annular passage 9d, whence an additional passageway 91 leads forwardly to communicate with chamber 92 which in turn terminates at the annular discharge opening 16. Control of the air llow from passage 9i to chamber 92 is by means of a manually controlled needle valve 93.

Suitable sealing means is provided at 94- to prevent the leakage of resin along the outer surface of the hollow needle 70.

The operation of the form of device shown in FIG. 5 and FlG. 6 should now be apparent. With a source of resin or other base material connected at lll, with a source of catalyst or other hardening material connected at 34, and with a source of air or other iluid pressure connected at 220, the device is ready to operate. The operator introduces air through the connection 22th by means of a control valve, not shown, thus causing the piston 25d to move rearwardly. The first action of the piston is to lift the needle valve 7S from its seat 72 by means of the rigid connection between members and 24?. This causes an initial low of the catalyst or hardening material from connection S4 through passageways 80, 7ib, 79, openings 7S, and passageway 7l to the: discharge end of the gun. This llow is controlled by means oi the adinstable needle valve 83 which is immediately in front of the operator for setting. As soon as the lost motion at 94 is taken up, which is of course almost immediately, the shoulder Zftlb engages the ange 73a to pull the hollow needle 7d rearwardly so as to open up the resin ilow around the tip of the needle 7b inside the fluid tip l2. The amount of this opening is set by the adjustment of the position of the hollow stem 35 by means of the control head a. When the llange 74C of the piston eX- tension '7d strikes the shoulder abutment 35e of the hollow stem 85, the rearward movement of the piston 25@ is stopped and this gives a controlled opening for the flow ot resin at the discharge end of the gun. Simultaneously with the introduction of air to the interi-or of cylinder Zltl, the air llows through the indicated passages to the air cap lill and emerges at 16 to control the fan or pattern of the air spray which thoroughly intermingles with the fluid components introduced at ll and 34, respectively.

This form of my invention in FIGS. 5 and 6 has all of the advantages of the previously described forms so that they need not be repeated here. Because the adjustable head 35a and the adjustable needle S3 are at the rear end of the gun and immediately available to the operator, he can quickly make positively indicated adjustments for the flow of the two components so as to obtain an exactly controlled mixture at the discharge end of the gun.

What is claimed is:

l. A multi-luid spray gun comprising a body having an open tip end and a central longitudinally extending opening from said tip end rearwardly, a hollow needle extending through said central opening, there being a chamber in said body near said tip end and having walls erminating in an annular opening surrounding said needle at said tip end and there providing an annular seat for said needle, sealing means between said needle and said chamber, said needle movable longitudinally in its associated opening to selectively close and open said annular opening, there being a rst supply passageway in said body communicating with said chamber for the supply or" a first huid thereto, there being a second supply passageway in said body and through the wall of said needle for the supply of a second fluid to the hollow of said needle, a needle valve extending centrally and longitudinally from said second supply passageway rearwardly, a valve seat in said needle at the rear end of the hollow thereof and axially opposite said needle valve, said needle valve movable longitudinally of said hollow needle selectively to seat-closing and seat-opening position, a needle valve actuator operatively connected with the rear end of said needle valve, there being a lost-motion connection between said actuator and said hollow needle the lostinotion of which is 4adapted to be taken up by slight opening movement of said needle actuator, adjustable stop means on said gun for limiting opening movement of said needle, and means for causing quick opening movement of said needle valve and needle in that order.

2. A spray gun as in claim 1 including nieans on said gun for controlling the ilow through said needle valve.

3. A spra gun as in claim l wherein said needle valve passes through said actuator to the rear end of said gun and has a threaded connection with said actuator, and means at the rear end of said needle valve for adjusting said threaded connection, whereby a iixed ratio is maintained between the amounts of said first and second tluid discharged from the gun.

4l A spray gun as in claim 1 wherein said actuator is a power means.

5. A spray gun as in claim l wherein said last named means is a cylinder and piston motor including a cylinder rigidly connected at the rear end of said gun, a piston reciprocatable in said cylinder at the rear end thereof, means for admitting air to the forward end of said cylinder to drive said piston rearwardly, spring means 0peratively connected with said piston to urge it forwardly, a hollow air cap at the tip of said gun closed except for an annular opening surrounding said chamber walls delining said iirst named annular opening, there being air passage means connecting the hollow of said air cap with the forward end of said cylinder, whereby admission of air to said cylinder causes opening of said needle valve quickly followed by opening movement of said hollow needle and simultaneously air is discharged from said last named annular opening.

6. The combination of claim 5 wherein said adjustable stop means comprises a hollow stem threaded into the rear end of said cylinder and abutting said piston, said needle valve passing freely through the hollow of said stern, and means for adjusting the position of said stern at the rear end thereof.

7. The combination ot claim 6 wherein said needle valve passes through said piston and has a threaded connection therewith, and means at the rear end of said needle valve for adjusting said threaded connection, whereby a lixed ratio is maintained between the amounts of said Erst and second tluids discharged from the gun.

8. A multi-huid spray gun comprising a body having an open tip end and a central longitudinally extending opening from said tip end rearwardly, a hollow needle extending through said central opening, there being a chamber in said body near said tip end and having walls terminating in an annular opening surrounding said needle at said tip end and there providing an annular seat for said needle, sealing means between said needle and said chamber, said needle movable longitudinally Cir in its associate-d opening to selectively close and open said annular opening, there being a lirst supply passageway in aid body communicating with said chamber for the supply of a rst fluid thereto, there being a second supply passageway in said body communicating with the hollow of said needle for the supply of a second huid to the hollow ot said needle, a valve seat in said needle interiediate its ends and communicating with the hollow thereof, a needle valve axially opposite said last named scat and movable to open and closed positions relative to said seat, a needle valve actuator operatively connected with the rear end of said needle Valve, there eing a lost-motion connection between said actuator and said hollow needle the lost-motion of which is adapted to be taken up by slight opening movement of said needle actuator, adjustable stop means on said gun for limiting opening movement of said needle, and means for causing quick opening movement of said needle valve and needle in that order.

9. Tl e combination of claim 8 wherein said last named means includes an air-operated abutment operatively connected with said needle valve actuator, there being an air chamber in said body contiguous to said abutment, means for supplying air under pressure to said air chamber, air oritice means radially outside said open tip end, and a passageway communicating between said air cha ber and said air orilice.

l0. A multi-fluid spray gun comprising a body having an open tip end and a central longitudinally extending opening from said tip end rearwardly, a hollow needle extending through said central opening, there being a chamber in sai-d body near said tip end and having walls terminating in an annular opening surrounding said needle at said tip end and there providing an annular seat for said needle, said hollow needle having its discharge end extending through said seat and forward beyond said seat, sealing means between said needle and said chamber, said needle movable longitudinally in its associated opening to selectively close and open said annular' opening, there being a first supply passageway in said body cornmunicating with said ciamber for the supply of a rst lluid thereto, there being a second supply passageway in said body communicating with the hollow of said needle for the supply ot a second lluid to the hollow of said needle, a needle valve extending centrally and longitudinally within said needle, a valve seat in said needle in the hollow thereof and axially opposite said needle valve, said needle valve movable longitudinally of said hollow needle selectively to seat-closing and seat-opening position, a needle valve actuator operatively connected with said needle valve, and means for causing quick opening movement of said needle valve and needle in that order.

References Cited in the file of this patent UNTED SEATES PATENTS 2,401,503 Paasche lune 4, 1946 2,907,527 Cummings Oct. 6, 1959 2,958,47l Zippel Nov. 1, 1960 FOREGN PATENTS 566,543 Great Britain Ian. 3, 1945 

